The brand new Jaguar I-PACE’s (earlier put up) electrical powertrain can function at currents of as much as 650 amps. To deal with these giant currents and the ensuing excessive load modifications, Continental developed a next-generation energy electronics system for Jaguar Land Rover that’s particularly tailored to the necessities of sporty, performance-oriented powertrains.
This progressive energy electronics resolution, which first went into manufacturing within the Vary Rover Sport Plug-in Hybrid (earlier put up), is designed for utility throughout all the future EV line-up of the 2 British premium manufacturers.
The facility electronics of hybrid and all-electric powertrains provides energy to the electrical motor, whereas additionally controlling the method of power recuperation. When it comes to operate, it acts as an interface between the high-voltage battery and the electrical motor.
For the reason that battery provides DC energy, however the motor runs on three-phase AC energy, the facility electronics should first convert the DC energy utilizing an inverter, earlier than supplying it on the required present and frequency to the motor. It’s these two electrical parameters that management the operation of the motor.
In recuperation mode, the facility electronics converts the AC present produced by the electrical motor into DC present, which is then used to cost the battery. It’s the energy electronics which decide whether or not the total potential of the electrical powertrain could be realized. In different phrases, the facility electronics is vital to maximizing the driving enjoyment related to the excessive low-end torque and instantaneous response that kind an inherent function of electrical motors.
In view of its key position within the electrical powertrain, the facility electronics is a part of main strategic significance. We’ve got been engaged in improvement work on this discipline for a very long time. In the present day, with the third era of our energy electronics know-how, we provide options for autos in all energy courses.
In designing the facility electronics for the Jaguar I-PACE and the Vary Rover Sport Plug-in Hybrid, we labored intently with Jaguar Land Rover to maximise the potential of our current-generation system, with a robust concentrate on sporty driving and excessive efficiency.—Christopher Breitsameter, Head of the Excessive Voltage Electronics Phase at Continental’s Powertrain division
The facility electronics should be able to supplying most present in fractions of a second—for instance, when accelerating at full throttle from standstill. The particular problem for the event crew was to accommodate such very excessive load modifications whereas on the similar time assembly the necessities anticipated of automotive programs by way of lengthy cycle life and repair life.
An extra improvement aim was a excessive power-to-size ratio, with the intention to shrink area necessities to a minimal. That it was potential to realize such a wonderful mixture of efficiency, lengthy life and compact dimensions is essentially right down to the progressive IGBT (insulated gate bipolar transistor) energy modules that are a key part of the inverter.
Sintered bonds on either side of the chip meet a lot increased calls for by way of service life, reliability and thermal tolerance than standard solder bonds, making this an answer significantly suited to the premium section. Continental is the primary firm to make use of this know-how in an automotive electronics utility.
Additional notable options along with the double sided sintered know-how embrace the usage of particular direct copper bonded substrates, often called DCB substrates, together with energy semiconductors which were constructed to order specifically for Continental. The general structure of the facility electronics, and the supplies used, are optimized for optimum energy and efficiency. The great collaboration with the Jaguar Land Rover venture crew, for which I ought to prefer to thank everybody concerned, was essential to the success of this venture.—Challenge Supervisor Alexander Reich
One other particular function of the newly developed energy electronics know-how is that the identical system can be utilized in fairly various kinds of car. For instance, the facility electronics within the Vary Rover Sport Plug-in Hybrid and the Jaguar I-PACE are fully an identical by way of —the one variations are within the software program.
Continental has lengthy been a know-how chief within the electrical mobility discipline. Its newest improvements embrace a whole EV axle drive system. This extremely built-in, scalable resolution brings collectively the electrical motor, transmission and energy electronics in a single module. This ends in each weight and effectivity benefits over comparable ideas, whereas having far fewer connecting elements additionally cuts prices. 120 kW and 150 kW variations of this electrical drive system are scheduled for launch within the Chinese language market in 2019.